WO1989001920A1 - Ceramiques renforcees avec des barbes et procede de revetement par pressage isostatique a chaud desdites ceramiques - Google Patents

Ceramiques renforcees avec des barbes et procede de revetement par pressage isostatique a chaud desdites ceramiques Download PDF

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Publication number
WO1989001920A1
WO1989001920A1 PCT/US1988/002690 US8802690W WO8901920A1 WO 1989001920 A1 WO1989001920 A1 WO 1989001920A1 US 8802690 W US8802690 W US 8802690W WO 8901920 A1 WO8901920 A1 WO 8901920A1
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WIPO (PCT)
Prior art keywords
compact
cutting tool
carbide
whisker
whiskers
Prior art date
Application number
PCT/US1988/002690
Other languages
English (en)
Inventor
Pankaj Kumar Mehrotra
Joyce L. Swiokla
Elizabeth R. Billman
Original Assignee
Kennametal Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kennametal Inc. filed Critical Kennametal Inc.
Priority to AT88908481T priority Critical patent/ATE91680T1/de
Priority to JP63507704A priority patent/JPH0647505B2/ja
Priority to KR1019890700791A priority patent/KR890701501A/ko
Publication of WO1989001920A1 publication Critical patent/WO1989001920A1/fr

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    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
    • B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
    • B23B27/148—Composition of the cutting inserts
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    • B23B—TURNING; BORING
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Definitions

  • Hot isostatic pressing With hot isostatic pressing, the powders are usually preco pacted and then the surface of the compact is, in some manner, sealed. The shapes are heated in a hot gas at high pressure. The gas transmits pressure to the compact because of the impervious surface. Hot isostatic pressing may take place at very high pressures for shorter times or at lower pressures for longer times. The particular approach to hot isostatic pressing depends upon the nature of the compact.
  • Ceramic cutting tools with a substantial second phase comprising carbide whiskers have recently been introduced. Typically, these compositions are formed by hot pressing. See Wei U. S. Patent No. 4,543,345 which teaches alumina-silicon carbide whisker co positions and teaches compaction by hot pressing. These tools are comprised of between 30 to 36 volume percent carbide whiskers. It is not possible to compact a composition with a substantial carbide whisker phase by simply presintering followed by hot isostatic pressing. See Becher and Tiegs U. S. Patent No. 4,657,877. In some way, the whiskers prevent the adequate densification and formation of an impervious surface during the presintering. Again, uniaxial hot pressing of whisker reinforced ceramics results in products having properties that are not all isotropic. Anisotropic properties develop as a result of the orientation of the whisker phase perpendicular to the pressing axis during pressing.
  • ceramic cutting tool compositions having a second phase comprising a substantial volume of ceramic (e.g., carbide) whiskers can be formed by hot isostatic pressing.
  • the random orientation of the whiskers may be measured by the X-ray parameter of whisker orientation to be explained herein.
  • the parameter preferably falls within the range 0.66 to 1.5 and most preferably falls within the range 0.8 and 1.25.
  • the fired ceramic product f has a density which exceeds 95 percent and, preferably, exceeds 97 percent of theoretical.
  • a method of manufacturing a shaped ceramic article by hot isostatic pressing comprising the following steps: (a) forming a compact of sinterable ceramic composition, (b) applying a coating to the compact by vapor deposition of a ceramic composition that does not become vitreous before or during the subsequent isostatic pressing step, and (c) heating and hot isostatically pressing the coated compacts in an atmosphere that reacts with the coating and/or the compact at pressing temperatures and pressures to cause the compact to approach theoretical density (i.e., exceeds 95 percent of theoretical) .
  • the method is particularly suitable for forming a compact of sinterable ceramic composition having 5 to 40, preferably 10 to 35 volume percent carbide whiskers.
  • the method is suitable for forming a fired ceramic compact having a whisker loading in excess of about 12.5 or 15 volume percent with substantially isotropic properties due to a substantially random orientation of the whiskers.
  • the method may also be used for forming ceramic compacts with less than about 12.5 volume percent whiskers, but these may also be made by other methods.
  • the method has particular advantages in forming a compact approximating the desired shape of a cutting tool. In this case the coating is ground away from the isostatically pressed compact and the compact is further shaped into a cutting tool insert having a cutting edge formed at the junction of a rake face and a flank face.
  • the methods according to this invention are particularly useful when the ceramic compact is comprised to a large extent of ceramic powders and carbide whiskers and the coating applied by vapor deposition is a refractory nitride, such as titanium nitride.
  • Vapor deposition includes chemical vapor deposition and physical vapor deposition.
  • the coating is between 5 and 50 microns thick and more preferably between 10 and 30 microns thick.
  • chemical vapor deposition takes place at about 1000°C by reaction of TiCl 4 , H 2 and N 2 .
  • a TiN coating is formed which is substantially unreactive with the presintered compact.
  • the gas used in pressuring the coated compact during hot isostatic pressing is nitrogen.
  • the heating and isostatic pressing take place in a nitrogen atmosphere at a pressure from 50 to 30,000 psi and temperatures from 1500 to 1800°C, most preferably 1700 to 1800°C. It is advantageous in most instances to provide an additional presintering step near atmospheric pressure and in a neutral or reactive atmosphere before the coating and hot isostatic pressing steps. This additional step does not make the following vapor coating step unnecessary with compacts such as those that comprise a high percentage of ceramic whiskers but tends to improve the properties of the hot isostatically pressed compacts and also tends to increase the yield (percentage of compacts adequately densified by the hot isostatic pressing) .
  • a ceramic composition comprising powdered oxides and carbide whiskers, especially silicon carbide or titanium carbide, is compacted, presintered, coated with a nitride, especially titanium nitride, and hot isostatic pressed in a nitrogen atmosphere to near theoretical density.
  • a multiple layer coating is applied to the compact prior to hot isostatic pressing.
  • Each layer has a different composition.
  • the layer adjacent to the compact may be an oxide that has a coefficient of thermal expansion between that of the fired compact and the outer coating.
  • an inner coating applied by chemical vapor deposition may be alumina and the outer coating applied by either chemical vapor deposition or physical vapor deposition or both may be titanium nitride.
  • the sinterable ceramic in addition to the carbide whiskers, comprises a finely divided component that after sintering provides the matrix between the whiskers.
  • the finely divided component is preferably an oxide ceramic and most preferably high purity alumina.
  • Other finely divided materials for providing the matrix phase comprise, for example, mullite, alumina-zirconia blends, silicon nitride, sialons and B 4 C.
  • Fig. 1 is a plot of density (percent of theoretical) versus volume percent silicon carbide whisker content at various processing stages (green, presintered at 175 . 0°C, CVD clad, and hot isostatically pressed) for ceramic compositions of interest.
  • Fig. 2 is a plot of density (percent of theoretical) versus presintering temperature (°C) for a composition comprising 35 volume percent whisker content at various processing stages.
  • Fig. 3 is a plot of yield (percent of compacts densified during the hot isostatic pressing step) versus presintering temperature for a composition comprising 35 volume percent whisker content.
  • Fig. 4 is a plot of hardness (Rockwell A) after presintering at 1750 ⁇ C, CVD cladding and hot isostatic pressing versus volume percent of whisker content and a plot of hardness versus whisker content for comparative hot pressed compositions.
  • Fig. 5 is a plot of toughness (K IC values measured in accordance with Evans & Charles, “Fracture Toughness Determination by Indentation,” American
  • Fig. 6 is a plot of hardness (Rockwell A) after presintering at 1750°C, CVD cladding and hot isostatic pressing versus presintering temperature for a composition comprising 35 volume percent whisker content and a plot of comparative data for hot pressed compositions at various hot pressing temperatures.
  • Fig. 7 is a plot of toughness (K 1C Evans & Charles) versus presintering temperature for a hot isostatically pressed composition comprising 35 volume percent whisker content and a plot of comparative data fo hot pressed compositions at various hot pressing temperatures.
  • Fig. 8 is a plot of tool-life (in minutes cutting Inconel 718 at 1000 sfm and 0.01 ipr with a depth of cut of 0..1- inch) versus volume percent silicon carbide whiskers in alumina compositions CVD clad and hot isostatically pressed according to this invention and a plot of tool-life versus whisker content for comparative hot pressed compositions.
  • Ceramic cutting tool inserts were prepared by hot isostatic pressing alumina and silicon carbide batches in which the silicon carbide was in the form of whiskers. The pressed compacts were tested for inherent properties and for suitability for machining. Suitability for machining was determined by fabrication of tool inserts from the compacts and using the tool inserts under severe machining conditions.
  • the starting materials for the preparation of the cutting tool inserts were premilled alumina powder, silicon carbide whisker powder, yttrium oxide powder (Y 2 0 3 ) and magnesia powder (MgO) .
  • the powders were blended together to form batches having the volume compositions- set forth in Table 1.
  • a very high purity alumina is used, say 99 percent by weight pure.
  • Alcoa's A16-SG is an acceptable ingredient in the above-described mixes.
  • the alumina is milled to a median particle size of 0.5 to 0.6 microns before blending with the ultrasonically dispersed silicon carbide whiskers.
  • the silicon carbide whiskers will have a purity in excess of 98 weight percent.
  • the silicon carbide whiskers may have a length of 20 to 150 microns with a diameter ranging from 0.3 to 0.7 microns. The aspect ratio will vary from 20 to 70-.
  • the mixes of Table 1 were each blended together to form a homogeneous blend and then cold isostatically compacted to form green compacts. There ⁇ after, the green compacts were presintered under one atmosphere pressure in argon gas between 1700 and 1800°C. The presintered compacts were then encapsulated with a TiN coating by standard chemical vapor deposition (CVD) techniques at 1000°C at sub- atmospheric pressure to provide a coating that was between 15 and 30 microns thick. The thickness of the coating was determined from polished sections. The coated or clad compacts were then hot isostatically pressed in a nitrogen gas atmosphere at between 15,000 and 20,000 psi at 1750°C. The parts were then ground to remove the cladding.
  • CVD chemical vapor deposition
  • the densities of each compact were determined in the green, sintered, clad and isostatically pressed condition. Referring to Fig. 1, the green density of these compacts ranged from 44 to 53 percent of theoretical, dropping with increasing whisker content. On presintering, the densities were raised to range from 62 to 94 percent of theoretical. For compositions made from Mix A (the lowest whisker content) , the presintered density may have been sufficient to permit hot isostatic pressing without cladding. But, for the compositions made from Mixes B to E (15 or more volume percent whiskers and presintered densities less than 90 percent) , cladding is essential prior to hot isostatic pressing.
  • compositions were densified by hot isostatic pressing—those with less than 25 volume percent whiskers to a density better than or equal to that achieved by hot pressing.
  • the densities were somewhat lower than that achieved with hot pressing.
  • the manufacturing advantages outweigh the disadvantages of somewhat lower density.
  • the effect of increasing the presintering temperature is to increase the presintered density and to increase the final hot isostatically pressed density.
  • the yield i.e., the percentage of compacts that show at least some densification (versus no densification at all) during hot isostatic pressing is clearly increased, however, by increasing the presintering temperature as shown by Fig. 3.
  • the quality of the coating applied by CVD in the case of the examples herein the titanium nitride coating, plays an important role in achieving better yields. Coating can be too thick resulting in flaking away of the coating from the presintered compact.
  • NW nose wear failure
  • BK breakage failure
  • FW flank wear failure
  • DOCN depth of cut notch failure
  • CH chip failure.
  • Titanium nitride appears to deposit on the open pores near the surface of the presintered compacts during the chemical vapor deposition. This causes a density increase with cladding which is directly proportional to presintered porosity.
  • the preferred chemical vapor deposition reaction is between TiCl 4 , H 2 and N 2 at about 1000°C. At this temperature a possible reaction with the SiC whiskers could result in the formation of Si 3 N 4 and carbon. However, very little SiC is converted by this reaction during CVD.
  • cracks may appear in the TiN coating due to the differential thermal contraction. The cracks should prevent the isostatic pressing of the clad compacts from working.
  • whisker orientation is required to fully appreciate the advantages of isostatic pressing of compositions with silicon carbide whiskers therein.
  • the X-ray parameter of whisker orientation was developed. This parameter is a measure of the degree of orientation of the whiskers in a fired ceramic compact.
  • a parameter of one is an indication of perfectly random orientation.
  • a parameter of more than one or less than one is an indication of orientation. The further the parameter is from one, the more oriented the whiskers in the compact.
  • the X-ray parameter is obtained by observing relatively strong X-ray diffraction peaks in a diffractometer corresponding to two crystallographic planes of the crystal structure of the whisker which planes form a dihedral angle that i's relatively large, preferably as close-as possible to 90".
  • a diffractometer corresponding to two crystallographic planes of the crystal structure of the whisker which planes form a dihedral angle that i's relatively large, preferably as close-as possible to 90".
  • X-ray diffraction readings are taken by irradiating two surfaces that are substantially perpendicular. For each surface irradiated, a ratio of the intensity of the two peaks selected for observation is computed.
  • the ratio of intensities would be computed by the following formula:
  • the rake face was irradiated for determination of the ratio P(perpendicular) and a flank face was irradiated for determining the ratio P(parallel) .
  • the intensities of the selected peaks may be inverted in each of the above formulas for P(parallel) and P(perpendicular) (so long as the same peaks are used for the numerator of each) and/or the parameter may be formed by inverting the right hand side of the above formula. Hence, a parameter of 1.5 would become .666. Each indicates the same degree of orientation of the whiskers.
  • the orientation or not of the whiskers can be observed by microscopic inspection of polished surfaces of the faces corresponding to those irradiated with X-ray.
  • the polished surfaces parallel and perpendicular to the direction of pressing will appear markedly different.
  • perpendicular polished surfaces will appear more similar.
  • the effect of the orientation of the whiskers upon certain physical properties of the ceramic compacts can be observed.
  • Palmqvist fracture toughness test is conducted, a Vickers indentation is produced on the polished surface and the cracks propagating outwardly from the four corners of the indentation are measured. The longer the average crack, the less tough the composition.
  • the ratio of the length of the cracks extending in perpendicular directions can be taken as a measure of the anisotropy of the toughness property.
  • present inventions may be used to fabricate substrate compositions described in P. K. Mehrotra et al copending application Serial No.092,113, which was concurrently filed with the present application, and P. K. Mehrotra et al copending application Serial No. 056,091, filed on May 28, 1987.
  • Application Serial No. 092,113 relates to articles of manufacture having a SiC whisker reinforced alumina matrix substrate which has an alumina coating bonded to its exterior surface. It has been found that these articles are useful as cutting inserts in the high speed rough machining of steels.
  • Application Serial No. 056,091 relates to a cutting tool composed of a ceramic composition comprised of 50 to 90 volume percent, alumina, 10 to 50 volume percent titanium carbide whiskers and up to 3 volume percent sintering aid residue.

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Abstract

Procédé de fabrication d'un article en céramique façonné par pressage isostatique à chaud comportant les étapes suivantes: a) formation d'un comprimé de compositions céramiques frittables; b) application d'une couche de revêtement par dépôt à la vapeur d'une composition céramique ne se vitrifiant pas avant ni pendant le pressage isostatique postérieur; c) chauffage et pressage isostatique des comprimés ainsi revêtus dans une atmosphère réagissant au revêtement et/ou aux comprimés aux températures de pressage, de manière que les comprimés approchent la densité théorique. Ce procédé est applicable à la fabrication d'une masse de céramique comprimée cuite ayant une charge de barbes supérieure à environ 12.5 % en volume, qui possède de bonnes propriétés isotropiques grâce à une orientation des barbes sensiblement aléatoire.
PCT/US1988/002690 1987-09-02 1988-08-08 Ceramiques renforcees avec des barbes et procede de revetement par pressage isostatique a chaud desdites ceramiques WO1989001920A1 (fr)

Priority Applications (3)

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AT88908481T ATE91680T1 (de) 1987-09-02 1988-08-08 Durch whisker verstaerkte keramik und verfahren zum heissisostatischen pressen der ummantelten keramik.
JP63507704A JPH0647505B2 (ja) 1987-09-02 1988-08-08 ホイスカー強化セラミツクス及びそれに対するクラツド／熱間静圧プレス成形法
KR1019890700791A KR890701501A (ko) 1987-09-02 1988-08-08 휘스커 보강 세라믹과 그것의 클래드/고온 이소스태틱 압분방법

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US07/092,118 US4820663A (en) 1987-09-02 1987-09-02 Whisker reinforced ceramic and a method of clad/hot isostatic pressing same
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DE4141366A1 (de) * 1991-12-14 1993-06-17 Mathias Dr Herrmann Verfahren zur herstellung von siliziumnitridsinterkoerpern mit modifizierter oberflaeche
EP0927709A1 (fr) * 1997-12-22 1999-07-07 Sandvik Aktiebolag Procédé de fabrication des céramiques renforcées par des whiskers
CN103011824A (zh) * 2011-09-28 2013-04-03 深圳光启高等理工研究院 一种超材料介质基板材料及其制备方法
US10544689B2 (en) 2015-10-06 2020-01-28 MTU Aero Engines AG Hybrid blade for turbomachines

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JP5991050B2 (ja) * 2012-07-04 2016-09-14 東ソー株式会社 セラミックス接合体の製造方法および装飾部材
CN103224403B (zh) * 2013-03-28 2014-10-22 佛山石湾鹰牌陶瓷有限公司 一种一次烧微晶玻璃复合板及其制造方法
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GB2211184B (en) * 1987-10-15 1991-10-23 Toshiba Ceramics Co A tool for machining a carbon material and process of producing it
EP0429420A2 (fr) * 1989-10-17 1991-05-29 Sandvik Aktiebolag Matériau céramique renforcé par les whiskers pour outils de coupe
EP0429420A3 (en) * 1989-10-17 1992-10-28 Sandvik Aktiebolag Whisker-reinforced ceramic cutting tool material
EP0426352A1 (fr) * 1989-10-30 1991-05-08 Corning Incorporated Procédé pour la production des matériaux composites à matrice céramique
DE4141366A1 (de) * 1991-12-14 1993-06-17 Mathias Dr Herrmann Verfahren zur herstellung von siliziumnitridsinterkoerpern mit modifizierter oberflaeche
EP0927709A1 (fr) * 1997-12-22 1999-07-07 Sandvik Aktiebolag Procédé de fabrication des céramiques renforcées par des whiskers
US6169048B1 (en) 1997-12-22 2001-01-02 Sandvik Ab Method of manufacturing whisker-reinforced ceramics
CN103011824A (zh) * 2011-09-28 2013-04-03 深圳光启高等理工研究院 一种超材料介质基板材料及其制备方法
US10544689B2 (en) 2015-10-06 2020-01-28 MTU Aero Engines AG Hybrid blade for turbomachines

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KR890701501A (ko) 1989-12-20
EP0377654A4 (en) 1991-05-22
CA1314908C (fr) 1993-03-23
CN1031996A (zh) 1989-03-29
JPH0647505B2 (ja) 1994-06-22
EP0377654A1 (fr) 1990-07-18
JPH03500639A (ja) 1991-02-14
DE3882533D1 (de) 1993-08-26
ATE91680T1 (de) 1993-08-15
CN1016164B (zh) 1992-04-08
DE3882533T2 (de) 1993-11-11
EP0377654B1 (fr) 1993-07-21
US4820663A (en) 1989-04-11

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